Abstract: A process for superplastically forming a tube of superplastic material to make a part includes sealing both ends of the tube with end caps to provide a sealed enclosed volume within the tube. At least one of the end caps has a connection that communicates between the enclosed volume and a gas line for connection to a gas management system for controlling forming gas pressure inside the enclosed space. The tube is inserting in a die and the connection is coupled to a gas supply line from said gas management system for supplying forming gas under pressure to said enclosed volume. The die and the tube are heated to the superplastic forming temperature for said material, and gas is introduced from the gas management system for pressurizing the enclosed volume with pressurized forming gas and for expanding the tube against the internal surfaces of the die.

Abstract: The present invention relates to a portable process for automated fastening of aircraft structures. The invention will employ two primary elements for locating and installing through-the-skin fasteners. Inside and outside units are attached onto an airframe and indexed to each other through coordination holes that have been pre-drilled through the structure. The aircraft structure is assembled with the pre-drilled coordination holes by aligning adjacent airframe parts and inserting alignment pins. The alignment pins will provide a degree of clamping to pull the parts together and provide indexing for inside and outside vacuum attachment track systems. The invention is equipped to traverse along the track system, accurately position itself, and drill only or countersink a hole, insert a fastener, and fasten, i.e., upset a rivet, or run down a threaded nut, then reposition itself to the next fastener location and repeat the process.

Abstract: The present invention relates to a racking fixture for holding components while they are electro-chemically processed. The fixture includes at least one shelf for holding the components and is electrically connected to a bus bar. A motor is mechanically engaged with the shelf and causes it to agitate to remove gasses trapped in components held on the fixture. The fixture also includes localized anodes for positioning adjacent to specific portions of the component.

Abstract: The present invention relates to an automatically reconfigurable contour checking fixture for comparing a component to a programmed contour. The fixture comprises a horizontal support table, having a length and width, wherein a drive rack runs along its length. The fixture also includes a plurality of stations positioned at intervals along the length of the support table, each of the stations including an artificial template member, and a multi-service drive assembly which drives the artificial template member of each of the plurality of stations to a respective designated point along the programmed contour. A computer is in communication with the multi-service drive assembly, communicating positional instructions such that the artificial template member of each of the plurality of stations conforms to the programmed contour.

Abstract: A method for forming a durable spliced sheet by splicing a plurality of components. Each component has a splicing edge and a core. The method comprises the steps of applying an adhesive, including graphite or fiberglass fibers, to the splicing edge of each of the components, aligning the splicing edge of each of the components with a respective contiguous counterpart, such that nodes of the core of each of the components match nodes on the contiguous counterpart, fastening the nodes of each of the components to the nodes of the aligned contiguous counterpart component, applying a uniform compressive pressure along the splicing edge, and heating the plurality of components to cure the adhesive and form the durable spliced sheet.

Abstract: The present invention relates to a method and apparatus for minimizing undesirable gaps in riveted assemblies. The method includes the steps of selecting a rivet having a head and a tail with identical forming characteristics, positioning the selected rivet in an assembly that is countersunk on one of two sides, and applying a force over time to the head of the rivet and a force over time to the tail of the rivet that are equal and opposite, compensating for force unbalancing characteristics of the countersink.

Abstract: The present invention relates to a protrusion sensor that determines the acceptability of a rivet within a component. The sensor includes a baseline detector which remains stationary, a movable detector which moves with a bucking bar module and produces a first signal proportionate to a distance between the baseline detector and the movable detector, and a CPU electronically connected to the movable detector and receiving the first signal.

Abstract: An airplane fuselage panel including a sheet having peripheral edges routed on routing surfaces, while the sheet is held immobile on a fixture, using a routing end effector carried by a precision computer controlled robot that is directed to the routing surfaces using a digital dataset taken directly from digital engineering part definition records. The sheet has coordination holes drilled while on the fixture using a drilling end effector carried by the precision computer controlled robot that is directed to drilling locations using the digital dataset taken directly from the digital engineering part definition records to accurately locate the hole locations relative to the peripheral edges.

Abstract: This invention is a countersink, counterbore or spotface, external pilot guide 98 which aligns a countersink cutter's edges 170, 171 and 172 into the center of a pre-drilled hole 15. The pilot guide indexes and attaches by lock down screw 165 to the countersink cutter 18 external body hole 160, three pilot legs 100 are recessed into the countersink cutter 18's flute pockets 150 and allows the cutting edges 170, 171 and 172 to extend through the pilot countersink cut-outs 140. Button nose 110 outside diameter comes in a range of sizes dependent on the pre-drilled hole 15 size (example: Pre-drilled hole size 0.375", button nose size 0.372") this allows clearance for friction expansion. All button nose 110 outside diameter's fit the same countersink cutter 18 and all have a hole in the center which allows the flare tube shaft 14 to move freely during the countersinking operation.

Abstract: A cooling apparatus for cooling a tool rotated by a spindle of a machining device. The cooling apparatus includes a tube having a plurality of orifices. The tube is mounted onto a stationary housing about the spindle to substantially encircle an axis of the tool. The apparatus also includes a plurality of nozzles connected to a respective one of the orifices, each of the nozzles directing a discharge of fluid substantially toward the tool.

Abstract: A tubular part formed by superplastic forming has a tubular structure made of superplastic material having a tubular wall with an outside surface like an inside surface of a die against which the tubular wall was superplastically formed by heating to superplastic forming temperature, and injecting the forming gas through connectors in end portions of the tubular structure, sealed against escape of forming gas from the tubular structure, to inflate the tubular structure against the inside surface of the die. Two open ends at opposite ends of the tubular wall are made by cutting off the end portions of the tubular structure. An integral projecting pull-out in the tubular wall for connection to a connecting tube is formed simultaneously with the tubular wall against a concave shape on the die.

Abstract: A device that automatically engages a contact, having a tip portion and a barrel portion, to a stripped end of an insulated wire. The apparatus includes a crimping gun having at least a pair of opposing jaws, and a push rod having a distal end that engages the tip portion of the contact and moves the contact to a pre-determined position between the jaws of the crimping gun. The device also includes a detector that sends out a signal upon sensing that the stripped end of the insulated wire has made contact with a rear most portion inside of the barrel portion of the contact, and a CPU in communication with the crimping gun and the detector. The CPU directs the crimping gun to crimp the contact to the stripped end of the insulated wire upon receipt of the signal from the detector.

Abstract: A system for loading parts to a workpiece clamp-up position on a floor assembly jig that holds the parts in position for fastening together into a large mechanical structure includes a frame mounted on slides adjacent to the floor assembly jig, and a mounting structure for temporarily mounting the parts on the frame. A powered lifting mechanism such as a crane lifts the parts onto the frame and then the frame can be slid laterally toward the clamp-up position on a floor assembly jig to position the parts for easy transfer onto the jig.

Abstract: The present invention relates to a lockbolt and a method for installing a lockbolt that removes a coating, such as a sealant that has inadvertently flowed into a hole into which the lockbolt is to be installed. The lockbolt and method prevent a coupling surface of the lockbolt from being contaminated by the coating.

Abstract: A probing system that checks a pattern formed by a plurality of features of an object. The system includes an input device that receives an ideal position and an ideal set of dimensions of each of the plurality of features, as well as an acceptable tolerance for the plurality of features. The input device generates a first signal. A probe device is electrically connected to the input device to receive the first signal, and in response, directs a probe to a location of samples. The probe device outputs a second signal indicative of a measured location of each of the samples.

Abstract: A process for seating a tight-fitting headed fastener in a hole in a workpiece so that the head of the fastener contacts the surface of the workpiece. The process includes inserting a distal end of the fastener, opposite its headed end, into the hole so that the distal end is tightly wedged into the hole and the headed end of the fastener is spaced from the workpiece surface. A driver of an electromagnetic impulse actuator is extended into contact with the fastener head, and the position of the driver when it is in contact with the fastener head is sensed and recorded to determine how far the fastener must be driven into the hole to seat the fastener head against the workpiece surface. A desired off-set distance of the driver from the fastener head is calculated which will result in seating of the fastener when the electromagnet impulse actuator is actuated, but will not cause excessive impact of the fastener head with the workpiece surface.

Abstract: An apparatus for measuring the amount of liquid in a tank mounted within a vehicle. The apparatus includes a tank-mount mechanically coupled to and surrounding the tank to prevent translational movement of the tank, The tank-mount has a plurality of pivoting members allowing only rotational movement of the tank. The members pivot about a common axis, defined by an orifice of each of a plurality of fixed members coupled to the vehicle. The tank-mount also has an extended end positioned on a side opposite to the plurality of pivoting members which extends outwardly from the tank. The apparatus also includes a load cell in contact with the extended end for providing a signal proportional to the load placed on the load cell by the extended end.

Abstract: A universal fixture holds a component relative to an established reference frame. The fixture includes a base fixable relative to the established reference frame, and a plurality of stanchions continuously movable along a plane defined by a surface of the base.

Abstract: An airplane fuselage including a plurality of individual subassemblies having components that are aligned using coordination holes. The components include an assembly of panels, a plurality of stringer clips, a plurality of frame members, shear ties, and a floor grid made of a plurality of crossmembers. The coordination holes are drilled in selected components and are located at positions on the subassemblies to accurately align the subassemblies relative to each other so the spatial relationship between key features of the subassemblies make them self-locating and intrinsically determinant of the final contour and configuration of the airplane fuselage, independent of hard tooling.

Abstract: A probing system used for determining a measured set of dimensions of at least one feature of an object. The system comprises an input device that receives an ideal set of dimension of the at least one feature. The input device generates a first signal indicative of an amount and location of sample measurements taken of the at least one feature. The system also comprises a probe device, which is electrically connected to the input device. The probe device receives the first signal from the input device, and in response directs a probe to the location of the measurements to be taken for each of the amount of sample measurements indicated. The probe device outputs a second signal indicative of a measured location for each of the amount of samples taken. The system further comprises a processor electrically connected to the probe device.